This procedure covers the removal and installation of both headlight assemblies on the 2024 Rivian EDV 500 electric delivery van, including electrical connector disconnection and front fascia access.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification
• Right headlight assembly × 1 — Use OEM specification
• Headlight mounting clip set (if damaged) × 1 — Use OEM specification
• Front fascia clips (replacement set) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been powered off for at least 10 minutes
3. Open front hood and secure with prop rod
4. Disconnect 12V battery negative terminal located in front storage compartment
5. Wait minimum 2 minutes for capacitor discharge
6. Cover front fenders with protective blankets to prevent scratches during work
7. Organize workspace and prepare magnetic parts tray for fastener storage

Procedure

1. 1

   Remove front wheel well liner access panels
   Turn the steering wheel fully to the left to access the right side headlight area. Remove the three Torx T25 screws securing the front portion of the wheel well liner. Fold back the liner to expose the rear of the headlight assembly. Repeat process on opposite side with wheel turned fully right.
2. 2

   Remove front fascia upper trim section
   Locate and remove the four Torx T30 screws along the top edge of the front fascia behind the hood opening. Carefully release the six plastic clips securing the upper fascia section using trim removal tools. Start from the center and work outward to prevent clip breakage. Remove the upper trim section and set aside in a safe location.
3. 3

   Access headlight mounting area
   With upper fascia removed, locate the headlight assembly mounting points. Identify three 10mm mounting bolts per headlight assembly: one on top near the hood latch area, one on the outboard side, and one on the lower inboard corner. Also identify the two electrical connectors on the rear of each headlight assembly.
4. 4

   Disconnect right headlight electrical connectors
   Starting with the right side headlight, press the release tab on the main headlight connector (larger connector with approximately 12 pins) and pull straight back. Then disconnect the secondary connector for daytime running lights/turn signals by pressing its release tab. Route connectors away from assembly to prevent damage during removal.
5. 5

   Remove right headlight assembly mounting bolts
   Remove the three 10mm bolts securing the right headlight assembly. Keep track of any spacers or washers on the bolts. The top bolt may have a ground wire attached - note its position for reinstallation.
6. 6

   Extract right headlight assembly
   With bolts removed, carefully pull the headlight assembly forward and outboard to release it from the locating tabs. Support the assembly weight with both hands. Tilt slightly as needed to clear the fascia opening. Place the removed assembly on a protected surface with lens facing up.
7. 7

   Disconnect left headlight electrical connectors
   Move to the left side of the vehicle. Press the release tab on the main headlight connector and pull straight back. Disconnect the secondary connector for daytime running lights/turn signals. Route connectors away from the assembly.
8. 8

   Remove left headlight assembly mounting bolts
   Remove the three 10mm bolts securing the left headlight assembly. Retain any spacers, washers, or ground wires attached to the bolts, noting their positions.
9. 9

   Extract left headlight assembly
   Carefully pull the left headlight assembly forward and outboard to release from locating tabs. Support the weight with both hands and tilt as needed to clear the opening. Place on a protected surface with lens facing up.
10. 10

    Prepare new headlight assemblies
    Unpack new headlight assemblies and verify they match the originals. Check that all mounting tabs are intact and that protective films are removed from lens surfaces only immediately before installation. Inspect electrical connectors on new assemblies for any shipping debris or damage.
11. 11

    Install new left headlight assembly
    Position the new left headlight assembly and align the locating tabs with their corresponding slots in the body structure. Tilt the assembly as needed to guide it into position. Once seated, ensure all tabs are fully engaged and the assembly sits flush with surrounding panels.
12. 12

    Secure left headlight mounting bolts
    Install the three 10mm mounting bolts with any spacers, washers, or ground wires in their original positions. Hand-tighten first to ensure proper alignment, then tighten evenly in a diagonal pattern. Verify assembly does not move when light pressure is applied.
13. 13

    Connect left headlight electrical connectors
    Connect the main electrical connector to the left headlight assembly, ensuring it clicks securely into place. Connect the secondary connector for DRL/turn signals. Gently tug each connector to verify positive engagement.
14. 14

    Install new right headlight assembly
    Position the new right headlight assembly and align the locating tabs with their corresponding slots. Guide the assembly into position, ensuring all tabs are fully engaged and the assembly sits flush with surrounding panels.
15. 15

    Secure right headlight mounting bolts
    Install the three 10mm mounting bolts with any spacers, washers, or ground wires in their original positions. Hand-tighten first, then tighten evenly in a diagonal pattern. Verify assembly is secure.
16. 16

    Connect right headlight electrical connectors
    Connect the main electrical connector to the right headlight assembly until it clicks. Connect the secondary connector. Verify both connectors are fully seated by gently tugging on them.
17. 17

    Reinstall front fascia upper trim
    Position the upper fascia section and align the plastic clips with their receiving holes. Press firmly starting from the center and working outward to engage all six clips. Install the four Torx T30 screws along the top edge and tighten evenly.
18. 18

    Reinstall wheel well liner access panels
    Fold the wheel well liners back into position on both sides. Install the three Torx T25 screws on each side to secure the liner sections. Ensure liners are not pinched or binding.

Reassembly

1. Reconnect 12V battery negative terminal
2. Verify all trim panels and wheel well liners are properly secured
3. Check for any tools or parts left in engine compartment or wheel wells
4. Remove fender protective covers

Verification

• Power on the vehicle and verify both headlights illuminate in low beam mode
• Test high beam function on both headlights
• Verify daytime running lights function on both sides
• Test turn signal operation on both headlight assemblies
• Check for any warning lights on instrument cluster related to exterior lighting
• Inspect headlight alignment - both beams should point straight ahead at same height (professional alignment may be required)
• Verify all fascia panels are flush and gaps are even
• Test adaptive headlight functions if equipped by turning steering wheel lock-to-lock with headlights on

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